Field formable step nose system

ABSTRACT

A step nose is formed having a tread portion and a riser portion, formed initially as a flat strip, the tread portion having a receiving slot formed therein, and the riser portion having a hook formed as part thereof. The tread and riser portions are stretchable with respect to one another so as to enable the hook to interlockingly engage the slot when the tread and riser portions of the flat strip are bent towards one another to thereby form a step nose ready for installation. Machines are further disclosed for forming the flat step nose strip into an assembled state by bending the tread and riser portions and interlocking them together.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalApplication Ser. No. 61/164,341, filed Mar. 27, 2009, entitled,“Improved Step Nose System,” the contents of which are incorporated byreference herein in its entirety.

FIELD

This disclosure relates to stair case systems and particularly to animproved step nose and step nose system mountable on stair step edges.

RELATED ART

Extrusions for application to staircase step noses to enhance visibilityand/or aesthetics in theatres and other venues are known.

SUMMARY

The following is a summary description of an illustrative embodiment ofan improved step nose system and components thereof. It is provided as apreface to assist those skilled in the art to more rapidly assimilatethe detailed design discussion which ensues and is not intended in anyway to limit the scope of the claims which are appended hereto in orderto particularly point out the invention.

In an illustrative embodiment, a step nose strip is formed having atread portion and a riser portion, formed initially as a flat strip. Thetread portion has a receiving slot formed therein, and the riser portionhas a hook formed as part thereof. The tread and riser portions arestretchable with respect to one another so as to enable the hook tointerlockingly engage the slot when the tread and riser portions of theflat strip are bent towards one another so as to form a step nose readyfor installation. The system may further include an end cap and a barbedharpoon connector for attaching the end cap to the step nose strip. Theharpoon connector is inserted in respective oppositely disposed openingsin the end cap and the step nose strip and thereafter firmly locks thetwo components together.

Illustrative embodiments are further disclosed of machines for formingthe flat step nose strip into an assembled state by bending the treadand riser portions and interlocking them together. In illustrativeembodiments, such a machine may comprise a first roller and a pluralityof cooperating guides for initially bending the step nose strip andthereafter feeding it to a wheel having a circular flange thereon whichcooperates with the first roller to stretch the riser portion of thestep nose downwardly and inwardly. A roller or mandrel at the end of themachine is positioned to push the hook portion of the riser portion intothe slot, thereby completing assembly.

Step nose strips formed according to various embodiments have theadvantage that they may be bent and interlocked into final shape in thefield, an operation which is facilitated by the disclosed bendingmachines.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a step nose system according to anillustrative embodiment;

FIG. 2 is a perspective view of the step nose component of the system ofFIG. 1;

FIG. 3 is a cross-section of the step nose component taken at 3-3 ofFIG. 2;

FIG. 4 is a cross-section of the step nose component in an assembledstate;

FIG. 5 is a top view of a harpoon connector component of the system ofFIG. 1;

FIGS. 6 and 7 illustrate end cap components of an illustrativeembodiment;

FIG. 8 is an end view of a wireway component of an illustrativeembodiment;

FIG. 9 is a perspective view illustrating a harpoon connector partiallyinserted into a step nose and adjacent end cap;

FIG. 10 is a perspective view of the step nose of the illustrativeembodiment being bent by hand;

FIG. 11 is a perspective view illustrating a method of interlocking ofthe step nose riser and tread portions of a step nose according to anillustrative embodiment;

FIG. 12 is a perspective view further illustrating the method ofinterlocking of the step nose riser and tread portions according to anillustrative embodiment;

FIG. 13 is a perspective view of an illustrative embodiment of a machinecapable of bending the tread and nose portions of the step nose of theillustrative embodiment and causing them to interlock;

FIG. 14 is a side view of the machine of FIG. 13;

FIG. 15 is an end view of the machine of FIG. 14;

FIG. 16 is a perspective view illustrating a step nose strip beinginitially fed into the machine of FIGS. 13-15;

FIG. 17 is a perspective view illustrating the step nose strip as itprogresses into the machine of FIGS. 13-15;

FIG. 18 is a perspective view illustrating the step nose strip beginningto engage a wheel component of the machine of FIGS. 13-15;

FIG. 19 is a second perspective view illustrating the step nose stripbeginning to engage the wheel component of the machine of FIGS. 13-15;

FIG. 20 is a perspective view illustrating the step nose strip engagingan end roller of the machine of FIGS. 13-15; and

FIG. 21 is an enlarged portion of the view of FIG. 20.

FIG. 22 is a first perspective view of an end cap according to anillustrative embodiment;

FIG. 23 is a second perspective view of an end cap according to anillustrative embodiment;

FIG. 24 is a perspective view of a machine capable of bending the treadand nose portion of the step nose strip of the illustrative embodimentand causing them to interlock;

FIG. 25 is an end view of the machine of FIG. 24;

FIG. 26 is a top view of the machine of FIG. 24;

FIG. 27 is a perspective view of a step nose strip being fed into themachine of FIG. 24;

FIG. 28 is an end view illustrating progress of the step nose stripthrough the machine of FIG. 24; and

FIG. 29 is an end view illustrating progress of the step nose strip intothe assembled state in the machine of FIG. 24.

DETAILED DESCRIPTION

An illustrative embodiment of an improved step nose lighting system 11is illustrated in FIG. 1. The system illustrated includes a folding stepnose component or extrusion 13, an end cap 15, and first and second endcap-connecting harpoons 17, 19. The system further may include a wireway21 comprising a wireway base 25 and a wireway cover 23. The wireway basecomponent 25 has an end 65 which meets flush with an end 67 of the endcap 15 and serves to guide and conceal electrical conductors, which passtherethrough. The illustrative system also includes a second end cap 16shown in FIG. 6.

In one embodiment, shown in FIG. 2, the folding step nose component 13is formed as a generally flat, bendable strip of flexible PVC(polyvinylchloride), also known as vinyl. In one embodiment, acontrasting light reflective strip 27 is co-extruded with the remainderof the step nose 13, which remainder is of a dark contrasting color suchas black. The light reflective strip 27 may, for example, be coloredwhite or off-white. Suitable PVC materials include, but are not limitedto, Geon flexible vinyl PVC injection molding material, UL Listed, RoHS,HB UL94, approx. 85 durometer shore A, as well as Geon Flexible VinylPVC C8000 Material.

As shown in the cross-section of FIG. 3, the step nose 13 includes atread portion 29 and a riser portion 31. A flexible web 30 interconnectsthe tread and riser portions 29, 31 as shown in FIG. 3. As illustrated,the tread portion 29 includes three generally rectangular openings orcells 33, 35, 37 which extend through the entire length of the step nosestrip 13. The riser portion 31 includes two generally rectangularopenings or cells 39, 41, which again extend through the entire lengthof the step nose strip 13.

In the embodiment illustrated in FIG. 3, the riser portion 31 of thestep nose strip 13 may lie at a slight angle to the horizontal asinitially formed, but the strip may be characterized as generally flatcompared to the assembled state of FIG. 4.

A hook 43 is further formed at the interior end of the riser portion 31,while a hook receiving slot 45 is formed on the interior end of thetread portion 29. As may be seen, the slot 45 is defined by a projectinglip 47. The lip 47 has an inner surface 49, which projects upwardly at aslight angle to the horizontal.

The hook 43 and slot 45 are dimensioned such that, as the riser portion31 is rotated in the direction of the arrow 51 in FIG. 3, the hook 43may be forced into mating relation with the slot 45 as shown in FIG. 4.In this position, in the illustrative embodiment, the riser portion 31lies at an angle θ of eighty degrees (80°) with respect to thehorizontally disposed tread portion 29. Because of the flexible natureof the material, the riser portion 31 may lie at various otherinstallation angles with respect to the tread portion 29 when assembledsuch as, for example, 90 degrees (FIG. 1) to accommodate various“kickbacks” of staircase designs. Illustrative dimensions of oneembodiment in inches are:

-   -   d₁=0.400 d₄=0.400 d₆=1.700 d₂=2.125 d₅=0.400 d₇=1.025        where d₁ is a height of the tread portion 29, d₂ is a width of        the tread portion 29, d₄ and d₅ are the widths of the respective        generally rectangular openings 33 and 41, d₆ is a width of the        riser portion 31, and d₇ is the width of the reflective strip        27. Such dimensions may of course vary in different embodiments.

An advantage of step nose constructed according to the illustrativeembodiment is that long lengths of flat strips such as shown in FIGS. 2and 3 may be readily shipped to an installation location, cut to length,and then bent into the configuration of FIG. 4 “in the field.” This is aparticular advantage where installation is to be done in a foreigncountry or where stair cases are of non-uniform width, e.g. decreasingin width from top to bottom in a “V-shape.” In other applications,factory cutting and bending to ordered length may suffice. Additionally,seamless lengths may be installed.

In one embodiment of the system, respective ends of a folding step nosesection 13 are finished by attachment of respective right and left endcaps 15, 16. As seen for example in FIGS. 6, 7, 22 and 23, the end caps15, 16 contain respective internal cells 233, 235, 237, 239, 241; 333,335, 337, 339, 341, which may have the same cross-section as the matingopenings 33, 35, 37, 39, 41 of the step nose strip 13. Each end cap 15,16 also has a respective tread portion 243; 353 and a respective riserportion 245; 355.

The end caps 15, 16 are preferably attached by respective “harpoon” endcap connectors, e.g. 17, 19, which are inserted in the top end mostcells and lower end most cells of the strip 13 and end connectors 15,16.

As shown in FIG. 5, each harpoon connector, e.g. 17, has a set 61, 63 ofbarbs or teeth on each end. One set of barbs, e.g. 61, is designed tobite into the interior wall of an opening in an end cap 15, 16, whilethe other set of barbs, e.g. 63, is designed to bite into the interiorsurface of one of the cells or openings in the step nose 13. In theillustrated embodiment, each set of barbs, e.g. 61, includes a number ofbarbs disposed along a first edge of the connector 17 and an equalnumber of barbs disposed on the opposite edge of the connector 17, eachrespective barb on one edge disposed opposite a corresponding barb onthe opposite edge.

In one embodiment, one harpoon connector 17 attaches the tread portionof an end cap 15 to the tread portion 29 of the step nose 13, while asecond harpoon connector 19 attaches the riser portion 31 of the end cap15 to the riser portion 31 of the step nose 13. In this manner, a verysecure connection and attachment of the end caps to the step nose 13 isachieved. In the illustrative embodiment, a harpoon connector isinserted into each of the openings 33, 41 in step nose 13 and intooppositely disposed openings in each end cap 15, 16.

As illustrated in FIG. 9, the width “W” from tip to tip of oppositelydisposed barbs may be just slightly greater than the width of the endcap and step nose-openings into which the harpoon connector 17 isinserted. In this manner, the relatively thin ends of the barbs 61, 63bend backwards to permit insertion and thereafter “bite” into thesurface of end cap or step nose strip openings. In one illustrativeembodiment, the harpoon connector 17 may be made from 18 gauge coldrolled steel or other metal and may have the following illustrativedimensions in inches (FIG. 5) W=4.75, d₈=0.125, d₉=1.130, θ₂=50 degrees.Various other dimensions may be used of course in various embodiments

As illustrated in FIG. 10, simply bending the step nose 13 of theillustrative embodiment shown in FIG. 3 by hand to rotate the riserportion 31 towards the tread portion 29 in the direction of arrow 51results in the back surface 42 of the hook 43 abutting the foot 44 ofthe receiving slot 45. In order to cause the hook 43 and slot 45 to matein interlocking relation, the riser portion 31 must first be stretcheddownwardly as shown in FIG. 11 and then moved inwardly as shown in FIG.12. Once the components are positioned as shown in FIG. 12, they simplyneed to be moved vertically with respect to one another to cause thehook 43 and slot 45 to engage or interlock.

A machine 71 for performing the operations necessary to interlock thetread and riser portions 29, 31 in the manner shown in FIG. 4 isillustrated in FIGS. 13-15. This machine 71 includes a first roller 73,which rotates about a horizontal axis disposed opposite a pair of guidesleeves, 75, 77, each rotatably mounted on respective vertical shaftsattached to a first horizontal arm 83. Rotating horizontal guide sleeves80, 82 are further provided beneath the first roller 173.

Adjacent the first roller 73 is mounted a separator wheel 85, which ismounted to rotate in a horizontal plane about a vertical axis. Theseparator wheel 85 has a circular flange 87 thereon. Across from theseparator wheel 85 are positioned two rollers, a pinch roller 91 and adeflection roller 93. These rollers or wheels 91, 93 each are rotatablymounted on respective vertical shafts 95, 97. In the illustrativeembodiment, the axes of these shafts 95, 97 are offset slightly suchthat the deflection roller 93 is inset slightly towards the wheel 85.The shafts 95, 97 are attached to a second horizontal arm 99 of anundercarriage 100. The wheel 85 is further rotatably mounted to a thirdarm 101 of the undercarriage 100, which is in turn rigidly attached to acentral post 103 rigidly attached to a flat rectangular base 105.

Operation of the machine 71 is illustrated in FIGS. 16-20. As may beseen, the tread portion 29 of the initially flat step nose strip 13 isfed into the machine 71 vertically between the first roller 73 andvertical sleeves 75, 77, while the riser portion 31 is fed inhorizontally between the first roller 73 and the horizontal sleeves 80,82, thereby bending the tread 29 and riser 31 toward one another.

As the step nose 13 is fed manually into the machine 71 and past thefirst roller 73, the first roller 73 and the lip 87 of the wheel 85cooperate to stretch the riser portion 31 downwardly and inwardly asshown in FIGS. 18 and 19, thus pushing the hook 43 of the riser portion31 over and opposite the slot 45 of the tread portion 29. As shown inFIG. 20, the deflection roller 93 completes the interlocking process bypushing the hook 43 into the slot 45 and thereafter releasing. FIG. 20also illustrates how the riser portion 31 is sandwiched between the lip87 and a rim 88 formed on the wheel 85.

In another embodiment, the feed mechanism may be automated, for example,by employing an electric motor and drive shaft to drive the large wheel85. One such embodiment may be configured to allow an electric drill todrive the large wheel 85. In some embodiments, teeth may be provided,for example, on the lip 87 and/or on the first wheel 73 to better gripthe step nose 13 and assist in feeding it through the machine 71.

A second embodiment of a machine 171 for interlocking the tread andriser portions 29, 31 is illustrated in FIGS. 24-29. This machine 171includes a first roller 173, rotatably mounted to a vertical arm 174,which is rigidly attached to a base platform 184. The first roller 173rotates about a horizontal axis and is disposed opposite a pair of guidesleeves, 175, 177, each rotatably mounted on respective vertical shafts179, 181 attached to a mounting block 183, which is rigidly attached toa base platform 184 by suitable fastening devices. Rotating horizontalguide sleeves 180, 182 are further provided beneath the first roller173. A third rotatably mounted vertical guide sleeve 176 is positionedon the base platform 184 in front and to the side of the first roller173.

Adjacent to the first roller 173 is mounted a separator wheel 185, whichis mounted to rotate in a horizontal plane about a vertical axis. Thewheel 185 has a circular flange 187 thereon. As seen in FIG. 25, theflange 187 is positioned above and spaced apart a distance D₁ from acircular plate 190. Another circular plate 197 is attached to the wheel185 and has a mounting block 192 attached thereto. A hand crank 194 isattached to the mounting block and is operable to rotate the wheel 185,flange 187 and plate 190 in unison.

Across from the wheel 185 is positioned a mandrel 191. As may be seen inFIGS. 28 and 29, the mandrel 191 has a conically shaped portion 195which diminishes in diameter and meets a cylindrical flange 197 at thetop of mandrel 191. The conical portion 195 forms into a cylindricalbottom section 194 which is rigidly attached to the base 184.

Illustrative dimensions of an illustrative machine 171 are shown in thetop view of FIG. 26. In this embodiment the outside (widest) diameter D₂of the mandrel 191 is 2.110 inches and its center 199 is spaced at adistance D₃ of 4.062 inches from the center 201 of the flange 187. Thediameter D₄ of the flange 187 and the circular plate 190 in thisembodiment is 5.990 inches. The horizontal axis 203 about which thewheel 173 rotates is positioned a distance D₅ of 3.470 inches from thevertical axis 201 about which the wheel 185, flange 187 and plate 190rotate. The angle of the conical edge of the mandrel 191 may lie atangle of 12 degrees from the vertical in one embodiment.

Operation of the machine 171 is illustrated in FIGS. 27-29. As may beseen, the tread portion 29 of the initially flat step nose strip 13 isfed into the machine 171 vertically between the first roller 173 andvertical sleeves 175, 177, while the riser portion 31 is fed inhorizontally between the first roller 173 and the horizontal sleeves180, 182, thereby bending the tread 29 and riser 31 toward one another.

As the step nose 13 is fed into the machine 171 and past the firstroller 73, the riser portion 31 enters the space between the flange 187and circular plate 190 (FIG. 28), and the hand crank 194 is operated topull the flat step nose strip 13 through the machine 171. As shown inFIG. 28, the flange 187 is dimensioned to engage the hook 43 and pushthe hook 43 and adjacent web surface 30 against the mandrel 191, therebypositioning the hook 43 opposite the receiving slot 45 of the treadportion 29. As seen in FIG. 29, as the step nose strip 13 proceedsfurther through the mandrel 171 and somewhat further past the mandrel191 the hook 43 moves into interlocking relation with hook receivingslot 45. The hand crank 194 is then continuously rotated to interlockthe hook 43 and slot 45 along the entire length of the step nose strip13. The hand crank mechanism 194 may again be automated, as discussedabove with respect to the first embodiment of FIGS. 13-21.

Those skilled in the art will appreciate that various adaptations andmodifications of the just described preferred embodiment can beconfigured without departing from the scope and spirit of the invention.Therefore, it is to be understood that, within the scope of the appendedclaims, the invention may be practiced other than as specificallydescribed herein.

1. Step nose system apparatus comprising: a step nose strip having atread portion and a riser portion; the tread portion having a receivingslot formed therein; and the riser portion having a hook formed as partthereof, the tread and riser portions being bendable and stretchablewith respect to one another so as to enable the hook to interlockinglyengage the slot.
 2. The apparatus of claim 1 wherein the hook is formedat an interior end of the riser portion, while a hook receiving slot isformed on an interior end of the tread portion, the slot being definedby a projecting lip having an inner surface which projects upwardly atan angle to the horizontal.
 3. The apparatus of claim 1 furthercomprising an end cap, and a barbed harpoon connector for attaching theend cap to the step nose strip.
 4. The apparatus of claim 3 wherein saidharpoon connector is inserted in respective oppositely disposed openingsin the end cap and the step nose strip.
 5. The apparatus of claim 1further comprising a machine for forming the step nose strip into anassembled state.
 6. The apparatus of claim 5 wherein said machinecomprises: a first roller and a plurality of cooperating guides forinitially bending the step nose strip; a wheel having a circular flangetherein and positioned to cooperate with the first roller to stretch theriser portion of the step nose downwardly and inwardly; and a mechanicalelement positioned opposite said circular flange to push the hookportion of said riser portion into said slot.
 7. The apparatus of claim6 wherein said element comprises a roller.
 8. The apparatus of claim 6wherein said element comprises a mandrel.
 9. The apparatus of claim 1further including a flexible web interconnecting said tread portion andsaid riser portion.
 10. The apparatus of claim 9 wherein said treadportion comprises a central rectangular opening and first and secondrectangular openings disposed adjacent to and on opposite sides of saidcentral rectangular opening, each of the three rectangular openingsextending through the length of the step nose strip.
 11. The apparatusof claim 10 wherein said riser portion comprises first and secondrectangular openings disposed adjacent one another and each extendingthrough the length of the step nose strip.
 12. The apparatus of claim 4wherein the harpoon connector has a plurality of barbs on opposite edgesthereof and wherein the distance from a tip of one barb on one edge tothe tip of a barb on the opposite edge is slightly greater than thewidth of the respective end cap and step nose-openings into which theharpoon connector is to be inserted and wherein the tips of the barbsbend backwards upon insertion to enable insertion of the connector intothe respective openings and thereafter “bite” into the respective endcap and step nose openings.
 13. The apparatus of claim 1 wherein, afterinterlocking, the tread and riser portions are disposed at angle of lessthan ninety degrees with respect to one another.
 14. Step nose systemapparatus comprising: a step nose strip having a tread portion and ariser portion; the tread portion having a receiving slot formed therein;and the riser portion having a hook formed as part thereof, the hook andslot being shaped and dimensioned such that the hook may be forced intomating relation with the slot when the tread and riser portions are benttowards one another.
 15. The apparatus of claim 1 wherein the hook isformed at an interior end of the riser portion, while a hook receivingslot is formed on an interior end of the tread portion, the slot beingdefined by a projecting lip having an inner surface which projectsupwardly at an angle to the horizontal.
 16. The apparatus of claim 12wherein, after interlocking, the tread and riser portions are disposedat angle of less than ninety degrees with respect to one another. 17.The apparatus of claim 12 further comprising an end cap, and a barbedharpoon connector for attaching the end cap to the step nose strip. 18.The apparatus of claim 1 wherein said harpoon connector is inserted inrespective oppositely disposed openings in the end cap and the step nosestrip.
 19. The apparatus of claim 1 further comprising a machine forforming the step nose strip into an assembled state.
 20. The apparatusof claim 5 wherein said machine comprises: a first roller and aplurality of cooperating guides for initially bending the step nosestrip; a wheel having a circular flange therein and positioned tocooperate with the first roller to stretch the riser portion of the stepnose downwardly and inwardly; and a roller positioned to push the hookportion of said riser portion into said slot.
 21. A machine for forminga step nose strip into a bent installable form wherein the step nosestrip has a riser portion with a hook formed as a part thereof and atread portion having a receiving slot formed therein, the machinecomprising: a first roller and a plurality of cooperating guides forinitially bending the step nose strip; a wheel having a circular flangethereon and positioned to cooperate with the first roller to stretch theriser portion of the step nose downwardly and inwardly; and a mechanicalelement providing a surface disposed opposite said circular flange, saidsurface cooperating with said flange to cause interlocking of said hookwith said slot
 22. The machine of claim 20 wherein said elementcomprises a roller.
 23. The machine of claim 20 wherein said elementcomprises a mandrel.
 24. The machine of claim 22 wherein said surface isconically shaped.
 25. Step nose system apparatus comprising: a step nosestrip having a tread portion and a riser portion; an end cap; and abarbed harpoon connector for attaching the end cap to the step nosestrip.
 26. The apparatus of claim 25 wherein said harpoon connector isinserted in respective oppositely disposed openings in the end cap andthe step nose strip.
 27. The apparatus of claim 26 wherein the harpoonconnector has a plurality of barbs on opposite edges thereof and whereinthe distance from a tip of one barb on one edge to the tip of a barb onthe opposite edge is slightly greater than the width of the respectiveend cap and step nose-openings into which the harpoon connector is to beinserted and wherein the tips of the barbs bend backwards up oninsertion to enable insertion of the connector into the respectiveopenings and thereafter “bite” into the respective openings.
 28. Theapparatus of claim 2 further including a flexible web interconnectingsaid tread portion and said riser portion.
 29. The apparatus of claim 28wherein said tread portion comprises a central rectangular opening andfirst and second rectangular openings disposed adjacent to and onopposite sides of said central rectangular opening, each of the threerectangular openings extending through the length of the step nosestrip.
 30. The apparatus of claim 29 wherein said riser portioncomprises first and second rectangular openings disposed adjacent oneanother and each extending through the length of the step nose strip.